Quantitative assessment of RAM driven risk matrix of offset printing machine

Summary Such classic risk-assessment techniques as failure mode and effect analysis(FMEA) and fault-tree analysis (FTA) are in common use by engineers but have anumber of shortcomings. Dynamic simulation, a new computer technique, countersmany of these deficiencies by introducing a time element that accommodatesrealistic component-failure characteristics and testing and inspectionactivities. This paper demonstrates how FMEA and FTA have been used to helpdesign North Sea well completions and how dynamic simulation models complexsystems realistically to allow comparison of designs and to provide insightinto operating availability and component-testing frequencies. Introduction Both single- and dual-string gas-lift completions are commonly used in theNorth Sea, but it is not obvious which design provides greater safely andreliability. The single completion (Fig. 1) with annular safety valve issimpler to operate and to work over, but during normal production, it has alarge volume of high-pressure gas beneath the tubing hanger that acts on thehanger, tubing spool, production casing, and wellhead seals. The alternativedual-string design (Fig. 2), in which production is routed through the longstring and injection gas through the second or short string, reduces the gasinventory above the safety valve and removes the lift-gas pressure from theannulus. It is a more complicated system to operate and to maintain, however, and it has more component parts. To assist with the selection of completiontype, a conventional risk analysis was undertaken to rank the risks associatedwith each completion during both production and workover modes and to identifycritical components to allow for possible design changes. An FMEA provided aqualitative comparison of the two designs, and an FTA quantified the risks. While these static techniques successfully identified the critical components, they could not address such problems as changes in the well system withproblems as changes in the well system with time, undetected failures, effectsof inspection and maintenance, or components with failure distributions otherthan exponential. Use of a dynamic simulator, which simulates the performanceof the completion throughout many life cycles, provided a more realistic riskassessment and allowed sensitivity tests to be performed on maintenance andtest frequencies and undetected failures. We assumed that such conditions aswater cut and reservoir pressure were identical for both completion types. Theoretically, the influence of such conditions and the effect of varyingequipment sizes can be modeled by adjusting the reliability data, but eachspecific situation requires its own analysis. Reliability data were provided byRefs. 1 and 2, in addition to some proprietary data. Uncertainties are alwaysassociated with reliability data, and the application of the data isnecessarily based on judgment. Risks expressed numerically should be treated ascomparative rather than absolute. Note that, in the static and dynamic studiespresented here, different types of failure presented here, different types offailure distributions were used because more realistic distributions dmexponential ones were available for use in the dynamic simulation. Static Analysis FMEA. After definition of the two well systems to be compared (Figs. 1 and2), the first step in assessing the reliability of each system was to preparean FMEA. This involved identification of possible component failures and theirconsequences to provide a qualitative comparison of the inherent risks in eachsystem. To provide a basis for comparison of the FMEA for each well system, weprepared a list of very critical events (VCE's) prepared a list of verycritical events (VCE's) and critical events (CE's) to summarize each analysis. Events were defined as follows. VCE (Severity 1): loss of control of the well, possible loss of life, and evacuation necessary. CE (Severity 2): loss of oneor more safety barriers but not all barriers, evacuation possible, and majorworkover required. possible, and major workover required. Comparison of VCE'sand CE's for each system provided a qualitative assessment as to which systemwas likely to be more or less hazardous. FTA. FTA techniques previously applied to well-completion designs were usedin this study to provide a quantitative comparison of different designs. TheFTA is based on the component identification carried out in the FMEA, but theFTA differs from the FMEA because it is a top-down approach. Therefore, the topevent of interest (i.e., catastrophic wellhead-system failure) is defined and alogic tree is constructed of lower-level failures until the component-failurelevel is reached at the bottom of the tree. JPT P. 1374

<div class="htmlview paragraph">Fault tree analysis (FTA) evolved from the aerospace industry in the 1960’s. A fault tree is deductive logic model that is generated with a top undesired event in mind. FTA answers the question, “how can something occur?” as opposed to failure modes and effects analysis (FMEA) that is inductive and answers the question, “what if?” FTA is used in risk, reliability and safety assessments. FTA is currently being used by several industries such as nuclear power and chemical processing. Typically the automotive industries uses failure modes and effects analysis (FMEA) such as design FMEAs and process FMEAs. The use of FTA has spread to the automotive industry. This paper discusses the use of FTA for automotive applications. With the addition automotive electronics for various applications in systems such as engine/power control, cruise control and braking/traction, FTA is well suited to address failure modes within these systems. FTA can determine the importance of these failure modes from various perspectives such as cost, reliability and safety. A fault tree analysis of a car starting system is presented as an example.</div>

Objective To investigate IMRT planning process using the combined application of failure modes and effects analysis (FMEA) and fault tree analysis (FTA) by reference to the report of Task Group 100 of the AAPM, and stablish and optimize the quality. Methods A multidisciplinary team detailed the process mapping of IMRT planning using Eclipse TPS. The team evaluated the potential failure modes (FMs) of every process step. The evaluation was divided into two groups according to whether quality management (QM) was considered. For every FM, occurrence (O), severity (S) and detectability (D) by consensus were evaluated, and the product of O, S and D yielded the risk priority number (RPN), which permitted the ranking of the FMs. Finally, FTA was used to determine the root factors contributing to the riskiest failure modes. Results The IMRT plan process consisted of 10 major sub-processes and 33 steps, which amounted to 47 failure modes. For the group without quality management, the RPN of FMs was between 13.2-271.8, 27 of which had RPN≥80, and 18 FMs had S≥8. For the group with quality management, the RPN of FMs was between 11.2-158.4, 11 of which had RPN≥80. The difference of RPN between the two groups was statistically significant (RPN of the group without QM=101.17±66.34, RPN of the group with QM=59.54±35.64, t=8.501, P<0.05). Finally, FTA was used to determine the root factors contributing to the FMs, i. e., prescription dose definition and importing images. Conclusions The FMEA and FTA methods are operable and practical, which can systematically and comprehensively analyze the potential failures and risks existing in the process of IMRT plan. And the FMEA and FTA can contribute to establish and optimize the quality management program in radiotherapy. Key words: Intensity modulated radiotherapy; Failure modes and effects analysis; Failure tree analysis; Quality management

Foamed asphalt is the main means of achieving largescale road repairs. Small foam asphalt mixture mixers are necessary test equipment before the road construction process. To avoid serious injuries due to equipment failure, the structural reliability of the mixer is analyzed using failure mode and effects analysis (FMEA) and fault tree analysis (FTA). Foamed asphalt is a metastable state product, and the mixer operation requires immediate and efficient operation, which results in a relatively complicated structure of the device. Potential faults are easily overlooked in reliability analyses of mixer systems. For FMEA, the familiarity proportionality coefficient should be introduced to ensure accurate ranking of the risk priority numbers and to reduce potential bias due to subjective evaluations by personnel. For FTA, the bottom event with the lowest probability of failure is removed while the bottom event with the smallest risk priority numbers and correlations are combined. The obtained FMEA table and structural fault tree model can improve the accuracy of the risk priority numbers, effectively reduce the workload of the reliability analysis, and obtain the structural reliability with less data.NomenclatureFoamed asphalt. Small foam asphalt mixture mixer. Risk priority number. Fault tree analysis. Failure mode and effects analysis. Reliability. The familiarity ratio coefficient of the scorer.

Hydropower generation is world best source of renewable energy and is continuously playing a tremendous job in energy requirement. To cope up with day by day increasing demand in electric energy, it is very essential to keep the hydropower plants in sustainable operational condition. To achieve this, the maintenance strategies based on Reliability, Availability and Maintainability (RAM) analysis play a pivotal role in sustainability of the hydropower plants. In our case study various critical components of hydropower plant were identified such as turbine, governor and generator. The causes and effects of various failures in the critical components were identified using Failure Mode Effect Analysis (FMEA) and Fault tree Analysis (FTA). The main role in the study is presenting a RAM model which helps in evaluating different levels of performance in Hydropower plant. Finally, the RAM parameters were evaluated and their outcomes were suggested to find the convenient maintenance intervals. The results of the proposed model revealed that the critical flaws of the hydrogenation process such as turbines, governors and generator should to be taken on priority basis to achieve the high level of reliability and safety. The results of present framework is to achieve the high level of reliability, hence, the main flaws of the hydrogenation process such as turbines, governors and generator should to be taken on priority basis. The proposed study could be valuable for improving the availability and safety of the critical equipment in hydropower plant. As a consequence, the results of present study could be beneficial for other hydro generating facilities to achieve the sustainable maintenance and operation programs in electricity generation systems.

This paper introduces a formulation of appropriate risk estimation methods that can be used for improving of processes in the electronics area. Two risk assessment methods have been chosen with regard to the specifics of adhesive joining based on electrically conductive adhesives. The paper provides a combination of a failure mode and effect analysis (FMEA) and fault tree analysis (FTA) for optimizing of the joining process. Typical features and failures of the process are identified. Critical operations are found and actions for avoiding failures in these actions are proposed. A fault treehas been applied to the process in order to get more precise information about the steps and operations in the process, and the relations between these operations. The fault tree identifies potential failures of the process. Then the effects of the failures have been estimated by the failure mode and effect analysis method. All major differences between failure mode and effect analysis and fault tree analysis are defined and there is a discussion about how to use the two techniquescomplement each other and achieve more efficient results.

Firefighters have among the most physically and psychologically challenging jobs in the world, incurring more than 80,000 (NFPA, 2014) injuries each year. Firefighter training is crucial, as higher knowledge and experience levels are inversely proportional to their risk of injury or work-related illness (Gonzalez, 2002). However, a paradox is created in that the training itself is the third highest cause of firefighter injury (Burgess, 2014). Therefore, enhancing training safety is paramount to creating a safer overall work environment for firefighters. This study focuses on a particularly hazardous aspect of training; crawling. A crawling simulator used by the Opelika and Auburn Fire Departments was built into the back of a trailer and is located in Lee County, Alabama. A system safety analysis was performed incorporating the use of tools including a preliminary hazard list (PHL), preliminary hazard analysis (PHA), risk assessment matrix, fault tree analysis (FTA), and failure modes and effects analysis (FMEA). Several hazards were identified and assessed. Recommendations for abating these hazards are offered, specifically for hazards resulting from the lack of an evacuation plan and absence of an occupant monitoring system.

The Italian construction sector suffered more than the other industrial sector the negative effects of the world economic crisis. A consequence has been a change in its organization concerning labour and managent on the health and safety issues. Evidence of this can be found in an increase of fatal accidents and occupational diseases. In particular occupational diseases became a health concern in construction. The aim of the presented research work is to assess the hazard of asbestos fibres inhalation due to decommissing of old industrial promises with roofing of asbestos. The developed approach starts from a probabilistic assessment of the risk, using the Risk Analysis tools, the Fault Tree Analysis (FTA) and the Failure Mode and Effect Analysis (FMEA). Risk assessment through the FTA is based on a backward approach: it starts from the malfunction of the system, called Top Event, in order to look for the triggering causes (events); on the contrary, the FMEA analysis is based on a forward approach: they start from a set of events and go on in order to analyse what kind of malfunctioning these can generate in the system. Both the FTA and the FMEA are applied to three approved decontamination techniques (encapsulation, confinement and removal), and for each of them operational phases, equipment, building products and PPE (Personal Protective Equipment) are evaluated highlighting the procedures needed to operate in complete safety. With this approach the main factors that contribute to the increase of the risk of asbestos fibres inhalation are detected: preliminary analysis and assessment of the state of building decay, the use and maintence of PPE and machinery, and the supervision during main working phases.

Photovoltaic (PV) power plant projects in East Java often face challenges during the initiation phase due to inadequate risk assessments. This phase is crucial for ensuring the project's long-term success; however, suboptimal risk identification has caused project delays. In the risk assessment process, high-priority risks need to be mitigated, but differences in the methods used can result in varying risk priority outcomes. One of the methods that can be used is Failure Mode and Effect Analysis (FMEA), while according to internal regulations at PT PLN (Persero), the Risk Matrix is applied. By using these two methods, the differences in the resulting risk priority rankings can be identified. Both tools rely on evaluations from experts experienced in decision-making during the initiation phase of PV power plant projects. From the analysis, 12 risks were identified during the initiation phase of the Pagerungan Besar PV power plant project. The highest-priority risks identified include Suboptimal feasibility study (Risk Priority Number/RPN: 74.27), unfavorable outcomes for the organization/company (RPN: 68.96), lack of budget (RPN: 64.00), and stakeholder Intervention (RPN: 53.69). Meanwhile, by plotting the Severity Level and Occurrence Level of each risk on the Risk Matrix according to PT PLN (Persero) regulations, the highest-priority risks identified include Suboptimal feasibility study (Extreme Risk Level, Zone E5), location-related issues (Extreme Risk Level, Zone E5), non-compliance with regulations (Extreme Risk Level, Zone E5), and suboptimal project team (Very High Risk Level, Zone D5). The two risk assessment methods produced different prioritizations, potentially impacting mitigation strategy decisions. This variation highlights the need for further analysis to ensure accurate and reliable risk prioritization, which is critical for project success and efficient resource allocation. Future studies should focus on evaluating prioritization methods to support effective decision-making and ensure timely project implementation in line with the targeted Commercial Operation Date (COD).

There are two issues to be addressed in the automatic Fault Tree Analysis (FTA) and Failure Mode and Effect Analysis (FMEA) approaches: resource fault and channel fault are not considered when generating the artifact flow graph (AFG) from Little-JIL processes. The AFG is incomplete, thus the fault trees and FMEA reports automatically generated partially based on AFG is incomplete. In this paper, we put forward to an approach of introducing resource instances and channel instances into fault propagation in Little-JIL processes. Thus, it makes the FTA and FMEA for Little-JIL processes to be much more effective. That is to say, how resource instances and channel instances might affect the fault propagation in Little-JIL processes is taken into account while performing these two automatic safety analysis techniques.

The hazard analysis and management is vital in textile industry to avoid accidents and wasting resources caused by the failures in production systems. Risk analysis is also very significant to decrease possible hazards and to avoid possible damage in manpower &amp; production systems. In this study, an approach based on Failure Mode and Effects Analysis (FMEA) and Fault Tree Analysis (FTA) is proposed to analyse the ring spinning yarn production process in a textile industry. First, the possible hazards in the production line, yarn production system, in an integrated company operating in the textile sector are analysed by FTA method. Then, FMEA is applied to ring spinning yarn production process in a textile industry to rank all possible risks corresponding to hazards in descending order with respect to both occupational health and safety. It is very important to remove all possible hazards in textile industry to decrease the number of risks related to occupational health and safety. Therefore, in total of 57 hazard root causes are determined in the yarn production department. Subsequently, the faults related to the hazard root causes are examined by FTA and then risk corresponding to these hazards are prioritized by FMEA. The results obtained from the proposed FTA-FMEA approach show that decision makers and engineers can easily decrease the number of hazards and risks with respect to both occupational health and safety in practice

The hazard analysis and management is vital in textile industry to avoid losing customers and wasting resources caused by the failures in production systems. Risk analysis is also very significant to decrease possible hazards and to avoid possible damage in production systems. In this study, an approach based on Failure Mode and Effects Analysis (FMEA) and Fault Tree Analysis (FTA) is proposed to analyze the ring spinning yarn production process in a textile industry. First, the possible hazards in the production line, yarn production system, in an integrated company operating in the textile sector are analyzed by FTA method. Then, FMEA is applied to ring spinning yarn production process in a textile industry to rank all possible risks corresponding to hazards in descending order with respect to both occupational health and safety. It is very important to remove all possible hazards in textile industry to decrease the number of risks related to occupational health and safety. Therefore, in total of 57 hazard root causes are determined in the yarn production department. Subsequently, the faults related to the hazard root causes are examined by FTA and then risk corresponding to these hazards are prioritized by FMEA. The results obtained from the proposed FTA-FMEA approach show that decision makers and engineers can easily decrease the number of hazards and risks with respect to both occupational health and safety in practice.

This study aims to identify the Integration of Overall Equipment Effectiveness (OEE) and Failure Mode And Effect Analysis (FMEA) to Increase the Effectiveness of Screw Press Machines at PT. Beurata Subur Persada Nagan Raya Regency. Based on the results of the study showed that the effectiveness of the Screw Press for PT. Beurata Subur Persada is still in the effective category with an average Overall Equipment Effectiveness value of 86.14 percent. This means that the screw press machine used is still very effective in the process of pressing the FFB. From the results of the analysis of the six big lose factor, it can be seen that Reduced speed losses is a very significant factor in the decline in OEE values on screw press machines with an average of 52.69% or with a time of 130.47 minutes. The results of the FMEA analysis show that the RPN value the biggest is 180 in the breakdown losses for the type of broken shift failure then the second largest is 120 in the reduced speed losses for the type of failure the engine speed is reduced. The results of the FMEA weighting with the largest RPN (risk priority number) for each category are 180 and 120. Based on these results it is necessary to propose improvements to reduce the breakdown losses and reduced speed losses in the highest repair priority, namely broken beds and reduced engine speeds. Overcoming these problems can be done by doing preventive maintenance on a regular basis once a week to prevent damage by dismantling the machine and re-installing and tightening or replacing new components.

The new version of the GOST ISO/IEC 17025-2019 standard requires the laboratories to plan and carry out actions to eliminate risks and opportunities. Several management tools can be used to identify risks, such as Failure Tree Analysis (FTA), Failure Mode and Effects Analysis (FMEA), Ishikawa diagram, risk matrix, brainstorming, and etc. The result of risk identification in the laboratory is a risk register containing all potential risks that may arise during laboratory activities. FMEA is one of the such registries. The purpose of this study was to demonstrate the possibility of using the FMEA tool for risk assessment in a testing laboratory, taking into account the requirements of GOST ISO/IEC 17025-2019. Two processes were selected and used for FMEA analysis - review of requests, applications and internal laboratory control. As part of the analysis, point estimates (on a ten-point scale) of the Severity of Effect S, the Probability of Occurrence O, and the Likelihood of Detection D. Based on the scores, the risk priority number RPN is calculated. For nonconformities with the RPN value exceeded 100, corrective measures were developed that made it possible to reduce the RPN values to an acceptable laboratory level. It is recommended to analyze the processes using the FMEA method in order to identify the causes of nonconformities and prevent their recurrence periodically. Risk analysis and management are necessary to achieve the intended results in the activities of testing laboratories, maintain and improve the quality management system.

Modern microgrids are networked systems comprising physical and cyber components for networking, computation, and monitoring. These cyber components make microgrids more reliable but increase the system complexity. Therefore, risk assessment methods are an imperative technology for cyber-physical systems to ensure safe and secure operations. The authors propose a reliability approach that utilizes the failure modes of power and cyber network key components to perform the risk analysis in microgrids. In this work, the authors have used the Failure Mode and Effect Analysis (FMEA) approach for risk assessment of microgrid systems and determine the influence of various failure modes on their performance. FMEA is one of the most effective methods to assess the risk involving the cyber components. It is the method of examining components, modules, and subsystems to determine failure modes in a system and their causes and consequences. A novel approach is proposed to calculate risk priority numbers based on factors like severity, occurrence, and detection. A risk matrix is calculated from the proposed FMEA worksheet, which acts as a graphical representation for evaluating components risk based on risk priority number or criticality metrics.